ews

So while trying to adjust the position of my lighthead on the handlebar, I ripped out the power cable. Tried to feed the wire back into lighthead but that didn't work. Anyone know how to repair? Replacement lighthead costs $45 and while I might go that route, I want to try and fix mine first.

Also, what the white creamy stuff coming out of the hole I tried to feed the cable back into?

Thanks!

jsharr

try here

https://www.candlepowerforums.com/vb/....php?p=2960073

IN that thread, someone has torn one apart and posted pics. Might get you an idea of where to start.

DallasSoxFan

1. Figure out how to open it
2. Figure out where the wires go and solder them on
3. Figure out how to close it

Or, were you not looking for a wise *ss response?

rumrunn6

ask geomangear or send it to them for service

AdamDZ

Do you know hot to solder?

No: send if for service

Yes: unscrew the mount, unscrew the lens, pull the guts out, pay attention to the thermal compound (you may need more), solder the cables (it's very obvious), reapply/add thermal compound, put everything together.

ItsJustMe

I really don't intend to be snarky here, but the fact that you thought that just shoving the wire back in again might fix it indicates that you probably should either find someone else to help or just buy a new light head.

jsharr

He said he wanted to attempt to fix his before replacing the light head. How else does one learn than by trying. Just my two cents. If y'all know how hot to solder, where the wires go, etc. point him in that direction. Maybe tell him about your soldering rig, that the white paste is probably dielectric compound or thermal compound. I know very little about electronics, but have learned lots in this forum.

Not the Slowest

Try your local Radio Shack

ews

Thanks for the advice eveyone. I don't have a soldering iron, so I'm not really sure I'm going to be able to repair this myself.

Jtgyk

I'm experiencing close to the same problem. Wires not ripped out, but when installing on the other bike I jostled the wire when securing the O-ring around the handlebar. It worked sporadically if I managed to have the wire hanging at just the right angle, but completely gave up the ghost last night on the commute home. I always travel with backup so made it home with a minimum of cursing.

I've emailed twice so far without a response, but maybe response is already winging it's way to me over the interweb.

Seriously, I love the light and will probably just drop the $45 for a new head if needed.

Garfield Cat

A local T.V. and video repairman can help.

Jtgyk

OK just heard from Geomangear and my light is old enough that the warranty has expired....I didn't want to mess with it until I knew for sure that I wouldn't be voiding the warranty.

Bring on the learning experience!!! (cue ominous music)

ItsJustMe

Here's one photo of the inside:


I didn't take the circuitry out myself, so I don't know exactly where the power wires go inside.

However, at this point you have nothing to lose if you were just going to buy a new head anyway, so go for it! If you can find someone who has soldered before to help, your odds of success will go up a lot.

ews

^^^^ Red X ^^^^

Did that come from the CPF post above?

znomit

How old?
If you can get it apart and put up pics we can all post different opinions on what you should do to fix it. Wires shouldn't just fall out like that... maybe this is a design problem. Do you take the light on and off often?

Jtgyk

Got it October of 99

Only 1 wire came off and I just got it re-soldered back on. I could see where it was cold soldered and hadn't completely melted to the wire. It must have shorted out against something on the driver board as the star lights up very weakly like it's not getting enough juice. The green LED glows brightly though.

The light got transferred back and forth once or twice a month, depending on road conditions. Not even a weekly ritual.

Jtgyk

znomit,

just now looked at your links...you certainly must know what you're doing with those builds.

could the broken wire have messed anything up when it broke loose, perhaps shorting against something inside?

znomit

Yeah anything is possible once you start waving the wire around. Doesn't sound like you've abused the thing... A new lighthead every 5 months is going to get expensive...

Jtgyk

I may just try getting another star and driver and try putting them in the housing. It's be a shame to let the batteries, charger, and a great housing go to waste.

Here are the parts I have to choose from Any suggestions from an experienced builder?

AdamDZ

If you're willing to pay for shipping (Priority Mail would be like $5.50 each way) perhaps some of us, myself included, would be willing to fix it for you for free? I could fix it for you and send it back the next day.

Or, as mentioned above local TV/radio repair should be able to do this under 5 minutes.

Adam

Jtgyk

Just opened another email from Goeomangear sent a couple of days ago.

He's offered a replacement light-head at a discount so I'm going for it!

Thanks Geoman!

I may also try an electronics repair shop too....if I can find one.